GESTRA URS 60 Original Installation & Operating Manual Download Page 19

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URS 60, URS 61 - Installation & Operating Manual -

819634-00

Fig. 7

Fig. 8

Name plate/identification of URS 60 / URS 61

The date of production is printed on the back of the equipment.

Equipment

designation

Mains voltage/

Power

consumption/

IP rating/

Admissible

ambient

temperature

Disposal

information

Manufacturer

Safety

integrity level

Wiring

diagram

Safety

note

Equipment

function
CE marking

Appointed

authority

Universeller Sicherheitsbegrenzer
Universal safety limiter
Limiteur de sécurité universelle

55°C (131°F)

IP 40 (IP20)

7 VA

Betriebsanleitung
beachten

See installation
instructions

Voir instructions de
montage

0525

TÜV . SWB/HWS STW(STB) SWÜL . XX-XXX

GESTRA AG

Münchener Str. 77
28215 Bremen
GERMANY

Steuergerät

evice

ppareille de commande

Control D
A

IEC 61508 SIL 3

24 V

± 20%

URS 60

250V

T 2,0A

13 14 15

CAN-Bus

16 17

23 24 26 27

URS 60

In/Out

Supply

24V DC

Main

Supply

24V DC

Out 24V DC

Alarm

Test/Set

In 24V DC

Option

120

CH CL

Channel

Universeller Sicherheitsbegrenzer
Universal safety limiter
Limiteur de sécurité universelle

7 VA

Betriebsanleitung
beachten

See installation
instructions

Voir instructions de
montage

0525

TÜV . SWB/HWS STW(STB) SWÜL . XX-XXX

IEC 61508 SIL 3

24 V

± 20%

URS 61

GESTRA AG

Münchener Str. 77
28215 Bremen
GERMANY

250V

T 2,0A

13 14 15

16 17

23 24 26 27

URS 61

120

CAN-Bus

In/Out

Supply

24V DC

Main

Supply

24V DC

Alarm

Out 24V DC

Test/Set

In 24V DC

Option CH CL

Channel

55°C (131°F)

IP 40 (IP20)

Steuergerät
Control Device
Appareille de commande

urrent approval

Serial number

Summary of Contents for URS 60

Page 1: ...Original Installation Operating Manual EN English Safety Control Unit URS 60 URS 61 819634 00 ...

Page 2: ...IL 12 Perform an annual function test 12 Reliability data to EN 61508 13 Function 14 Possible combinations of functions and equipment 15 Technical data 17 Name plate identification of URS 60 URS 61 19 Factory settings 20 Safety control unit URS 60 20 Safety control unit URS 61 20 Functional elements and dimensions 21 Installing the URS 60 URS 61 safety control unit 22 Wiring diagram of the URS 60 ...

Page 3: ... test 29 Checking installation and function 30 System malfunctions 31 Causes 31 Check the installation and configuration before systematic troubleshooting 31 Indication of system malfunctions 32 What to do in the event of system malfunctions 34 Checking installation and function 34 Emergency mode 34 Emergency mode for water level limiter systems 34 Taking out of service 35 Disposal 35 Returning de...

Page 4: ...l unit URS 61 First edition BAN 819634 00 08 2019cm Copyright All rights reserved Any misuse particularly reproduction and dissemination to third parties is not permit ted The General Terms Conditions of GESTRA AG apply Scope of delivery Product package 1 x Safety control unit URS 60 or URS 61 1 x Installation Operating Manual ...

Page 5: ...nstructions Please also read the instructions for use of any accessories The Installation Operating Manual is part of the equipment package Keep it in an easily accessible location Availability of this Installation Operating Manual Make sure this Installation Operating Manual is always available to the operator If you pass on or sell the equipment to a third party please also hand over the Install...

Page 6: ...situation that results in death or serious injury WARNING Warning of a dangerous situation that may possibly result in death or serious injury CAUTION Warning of a situation that may result in minor or moderate injury ATTENTION Warning of a situation that results in damage to property or the environment ...

Page 7: ...al standard IEC 61508 forms the basis for establishing testing and operating technical safety systems CAN Controller Area Network bus Data transmission standard and interface for connecting electronic equipment sensors and control systems Data can be sent and received TRV NRG LRG SRL Equipment and type designations of GESTRA AG see page 10 PhotoMOS output PhotoMOS are a special kind of semiconduct...

Page 8: ...off the feedwater supply when the water exceeds the set maximum level Conductivity limiters in combination with conductivity electrode LRG 1x 6x Conductivity limiters switch off the heating when conductivity exceeds the set maximum level Safety temperature monitors limiters in combination with temperature transmitter TRV 5 60 Safety temperature limiters or monitors switch off the heating when the ...

Page 9: ... 1 Automatic electrical controls Part 1 General requirements EN 61508 Functional safety of electronic systems Standards documents VdTÜV Bulletin BP WASS 0100 RL Requirements for water level control and limiting equipment VdTÜV Bulletin BP WAUE 0100 RL Requirements for the testing of monitoring equipment VdTÜV Bulletin BP TEMP 0100 RL Requirements for the testing of temperature monitors and limiter...

Page 10: ... to EN 61508 NRG 16 60 NRG 17 60 NRG 19 60 NRG 111 60 NRG 16 61 NRG 17 61 NRG 19 61 NRG 111 61 TRV 5 60 URB 60 SPECTOR control SRL 6 60 SIL 2 to EN 61508 NRG 26 61 NRG 16 60 NRG 17 60 NRG 19 60 NRG 111 60 NRG 26 61 NRG 16 61 NRG 17 61 NRG 19 61 NRG 111 61 LRG 16 60 LRG 16 61 LRG 17 60 TRV 5 60 URB 60 SPECTOR control SRL 6 60 Fig 1 Key to Fig 1 NRG level electrode LRG conductivity electrode TRV tem...

Page 11: ...s to repair the equipment will cause the system to become unsafe Do not repair the URS 60 URS 61 safety control unit Only replace faulty equipment with identical equipment from GESTRA AG Required personnel qualifications Activity Personnel Integration in control system Specialist staff Plant designer Installation electrical connection bringing into service Specialist staff Electrician installer Op...

Page 12: ... safety characteristics in Fig 4 are based on the URS 60 URS 61 safety control unit including output contacts Breakdown of safety function failure rates Sensor probe The CANopen interface is a Black Channel type and can be ignored during calculation due to the low failure rate of 1FIT CANopen URS 60 URS 61 Burner safety circuit Sensor electronics Fig 3 Perform an annual function test Check the fun...

Page 13: ... failure fraction SFF 99 0 Test interval T1 1 year Probability of failure on demand PFD 20 0 10 5 Diagnostic coverage Percentage of dangerous failures detected by a test DC 99 0 Mean time to failure MTTFD 90 a Diagnostic interval T2 1 hour Performance level to ISO 13849 PL d Probability of failure per hour PFH 20 10 9 1 h Ambient temperature as a basis for calculation Tu 45 C Mean time to repair M...

Page 14: ...ay if the following error messages are received Fault in sensors negative self test excessively high temperature in terminal box Fault in control unit negative self test Communication failure Behaviour on the occurrence of error messages Cyclical self tests monitor the safety functions of the equipment in the safety control unit and sensors Error messages are updated with each self test If there a...

Page 15: ...RG 1x 60 NRG 26 61 STL STM 1 with temperature transmitter TRV 5 60 SCL 1 with conductivity electrode LRG 1x 6x SLLL 1 with level electrode NRG 1x 60 SLLL 2 with level electrode NRG 1x 60 NRG 26 61 STL STM 1 with temperature transmitter TRV 5 60 SLLL 1 with level electrode NRG 1x 60 SLLL 2 with level electrode NRG 1x 60 NRG 26 61 SHLL 1 with level electrode NRG 1x 61 NRG 26 61 STL STM 1 with temper...

Page 16: ...vel electrode NRG 1x 61 NRG 26 61 STL STM 2 with temperature transmitter TRV 5 60 STL STM 3 with temperature transmitter TRV 5 60 SCL 1 with conductivity electrode LRG 1x 6x STL STM 3 with temperature transmitter TRV 5 60 STL STM 3 with temperature transmitter TRV 5 60 STL STM 4 with temperature transmitter TRV 5 60 STL STM 5 with temperature transmitter TRV 5 60 STL STM 6 with temperature transmi...

Page 17: ...uired external fuse for safety circuit T 2 A or T 1A T slow blow for TRD 604 72 hrs of operation see page 9 Signal output 4 PhotoMOS outputs for external signalling with or without delay 24 DC max current load 100 mA NO characteristic Test input 4 opto coupler inputs for external test triggering high active 24 V DC 20 Output relay switch off delay Factory default setting 3 seconds Option of 10 sec...

Page 18: ...t temperature 40 C 80 C Air humidity 10 95 non condensing Altitude up to 2000 m Body Body material Lower section of black polycarbonate glass fibre reinforced front of grey polycar bonate 2 x 15 pole terminal strips removable separately Max cross section per screw terminal 1 x 4 0 mm2 solid or 1 x 2 5 mm2 stranded with sleeve or 2 x 1 5 mm2 stranded with sleeve Body attachment Mounting clip on sup...

Page 19: ...Y Steuergerät evice ppareille de commande Control D A IEC 61508 SIL 3 24 V 20 URS 60 250V T 2 0A 3s 6 10 13 14 15 7 2 CAN Bus 1 3 4 8 5 9 16 17 23 24 26 27 URS 60 In Out Supply 24V DC Main Supply 24V DC 1 1 2 Out 24V DC Alarm 2 Test Set In 24V DC 3 3 4 4 Option 120Ω CH CL Channel Channel Universeller Sicherheitsbegrenzer Universal safety limiter Limiteur de sécurité universelle 7 VA Betriebsanleit...

Page 20: ...delay OFF Configuration Operation e g with two level electrodes NRG 1x 60 Code switch setting sliding switch white 1 ON 2 3 4 5 6 7 8 9 10 1 ON 2 3 4 5 6 7 8 9 10 Safety control unit URS 61 Baud rate 50 kBit s max cable length 1000 m Signalling delay OFF Configuration Operation e g with one level electrode NRG 1x 61 Code switch setting sliding switch white ...

Page 21: ...baud rate E Front membrane with buttons and LEDs see page 29 F Body G Support rail TH 35 Functional elements and dimensions 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 100 73 118 1 2 MAX 1 27 16 17 18 19 20 21 22 23 24 25 26 28 29 30 A B C F G D E The code switch can be accessed by disconnecting and removing the lower terminal strip Equipment settings see page 27 Fig 9 1 12 13 14 15 MAX 1 27 6 28 29 30 ...

Page 22: ...is a risk of electric shock during work on electrical systems Switch off the voltage to the system before you install the equipment Check that the system is not carrying live voltage before commencing work 1 Switch off the voltage to the system or secure the surrounding equipment in the control cabinet if live so it cannot be touched 2 Carefully press the unit onto the support rail until the holde...

Page 23: ... 22 23 24 25 26 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 24 V DC 24 V DC Out 24 V DC 1 2 In 24 V DC CH CL S 120 Ω 250 V T2 O A 3 4 1 2 3 4 Supply voltage Safety circuit Supply In Out Test set channel Option Alarm channel 100 mA CAN bus CH CAN High CL CAN Low S Shield The URS 61 is connected as shown in the wiring diagram for the URS 60 ...

Page 24: ...th 24V DC Connecting the 24V DC I O interface The I O interface can be supplied with power either from the supply voltage of the safety control unit see above or via a separate 24 V DC voltage The signalling outputs and test inputs are wired using single core wires e g H07V U Instructions for connecting the safety circuit Connect the safety circuit to terminals 23 24 and 26 27 If using the equipme...

Page 25: ... connection to a central earthing point Connect the bus line shields to one another all the way along and connect them to the central earthing point CEP If two or more system components are connected in a CAN bus network a 120 Ω terminating resistor must be connected to the first and last units The URS 60 URS 61 safety control units have an internal terminating resistor To activate this internal t...

Page 26: ...he baud rate using the code switch D Fig 9 S9 see page 28 You must set the same baud rate for all bus participants You can change the factory settings of URS 60 URS 61 safety control units at any time Make changes before installing the safety control unit when access is easier You will need the following tools Slotted screwdriver size 2 5 Phillips screwdriver size 1 Proceed as follows 1 Unscrew an...

Page 27: ... necessary parameters With the lower terminal strip removed Using a thin blade screwdriver configure the code switch D see Fig 9 using switches S1 to S10 as shown in the table Next re install the terminal strip and tighten the fastening screws Code switch D sliding switch white 1 ON 2 3 4 5 6 7 8 9 10 Configuring the limiter function URS 60 URS 61 safety control unit Code switch D Limiter function...

Page 28: ... see table below URS 60 URS 61 safety control unit Code switch D Configuration S9 S10 Signalling delay Baud rate Factory setting OFF OFF OFF 50 kBit s OFF ON ON 50 kBit s ON OFF OFF 250 kBit s ON ON ON 250 kBit s The delay is the relay switch off delay of 3 seconds set ex works 10 seconds or 15 seconds optional When defining limiter functions 1 to 4 please also pay attention to the operating instr...

Page 29: ... signal an alarm Signal LED 1 2 3 4 one or more flash red rapidly The switch off delay is running the signal output closes with without a delay Signal LED 1 2 3 4 one or more light up red The delay time has elapsed the output contacts open The signal outputs close Test of limiters 1 4 In operating mode Press button 1 2 3 or 4 and hold until the end of the test The limiters must behave as if there ...

Page 30: ...t of limiters 1 4 tables it may be faulty Perform failure analysis Do not repair the URS 60 URS 61 safety control unit Only replace faulty equipment with identical equipment from GESTRA AG Checking installation and function Monitoring the switching points The switching points for low water high water and MAX temperature must be checked by reaching these water levels and temperature limits In this ...

Page 31: ...a 120 Ω terminating resistor connected to the terminal devices of the CAN bus line Control unit configuration Are the limiter function delay time and baud rate correctly set on code switch D Sensor configuration Are the sensors set to the correct limiter number 1 2 3 4 5 6 7 8 Baud rate Is the cable length correct for the set baud rate Is the baud rate identical for all units DANGER There is a ris...

Page 32: ...tput is closed Check the following points The wiring The baud rate The sensor limiter numbers Pay attention to the notes on page 31 Indication of malfunctions in limiter 1 4 LED 1 lights up yellow Limiters 1 4 Signal LEDs 1 4 Description Remedy One or more limiters are malfunctioning One or more LEDs flash green slowly The output contacts open without a delay The relevant signal output is closed C...

Page 33: ...losed Check the configuration of the URS 60 URS 61 and connected sensors Pay attention to the notes on page 31 Replace faulty units with an identical unit Indication of overheating in limiter 1 4 LED 1 3 light up yellow Limiters 1 4 Signal LEDs 1 4 Description Remedy One or more limiters indicate overheating One or more LEDs flash green slowly The output contacts open without a delay The relevant ...

Page 34: ...Emergency mode Emergency mode for water level limiter systems If the URS 60 URS 61 is working with two level electrodes NRG 1x 60 water level limiter system the equipment can continue working with one level electrode in emergency mode under constant supervision upon the failure of one electrode in accordance with TRD 401 EN 12952 and EN 12953 see page 9 The following settings are required 1 Remove...

Page 35: ...decontami nated before being returned or sent back to GESTRA AG The term media can refer to solid liquid or gaseous substances or mixtures as well as radiation GESTRA AG only accepts returned products with a filled out and signed return note along with a filled out and signed decontamination declaration The return confirmation and decontamination declaration must be attached to the outside of the ...

Page 36: ...ves Directive 2014 68 EU EU Pressure Equipment Directive Directive 2014 35 EU Low Voltage Directive Directive 2014 30 EU EMC Directive Directive 2011 65 EU RoHS II Directive Please see our Declaration of Conformity for details on the conformity of our equipment with European Directives The current Declaration of Conformity can be found online at www gestra com or can be requested from us ...

Page 37: ...37 URS 60 URS 61 Installation Operating Manual 819634 00 For your notes ...

Page 38: ...38 URS 60 URS 61 Installation Operating Manual 819634 00 ...

Page 39: ...39 URS 60 URS 61 Installation Operating Manual 819634 00 ...

Page 40: ... Bremen Germany Phone 49 421 3503 0 Fax 49 421 3503 393 e mail info de gestra com Web www gestra com 819634 00 08 2019cm 808940 00 GESTRA AG Bremen Printed in Germany You can find our authorised agents around the world at www gestra com ...

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